User manual GAS GAS WILD HP 450

MANUAL DEL USUARIO MANUAL DEL USUARIO SERVICE MANUAL SERVICE MANUAL MANUEL D'ENTRETIEN MANUEL D'ENTRETIEN LIBRETTO USO E MANUTENZIONE LIBRETTO USO E MANUTENZIONE PRESENTATION GAS GAS thanks you for your trust. By choosing the new WILD H.P. 450 you have just joined the great GAS GAS family and, as a user of the number one off-road manufacturer, you deserve the distinguished treatment that we want to offer to you, both in our after-sales relationship and with the explanations that we will give you in this manual. Our WILD H.P. is a sports four-wheel vehicle conceived in and for competition. It will help you appreciate a high degree of technical perfection and reliability, apart from a meticulous design and high performance. The present manual will offer you a good basic knowledge of the vehicle's characteristics and handling. It contains important instructions about your safety and information on the necessary skills and techniques required to handle it, as well as the basic maintenance and inspection proceedings. Thanks for your confidence and welcome to GAS GAS Motos, S.A. August 2003 WILD HP -68- COMMON ADVICE Read this manual thoroughly. It contains all the aspects that must contribute to your and other people's safety, and it also guarantees the correct conservation and maintenance of the GAS GAS vehicle that you have just purchased. READ THIS MANUAL THOROUGHLY BEFORE USING THE VEHICLE. Important information on this manual Not following the advice contained in the manual can lead to grave or even fatal injuries. Specially relevant information is highlighted in the manual with the notations below: WARNING PROTECTING THE FUTURE OF YOUR SPORT ENSURES THE LEGAL USE OF YOUR VEHICLE, WITH CLEAN CONSCIENCE OF THE ENVIRONMENT AND RESPECTING THE RIGHTS OF THE OTHERS. QUAD driving is a great sport, and we hope that you can fully enjoy it. This manual has been designed with the data and specifications available in the moment of its composition. Any difference that may be appreciated with your vehicle will be due to improvements in riding and the product's quality. GAS GAS Motos SA is constantly improving their vehicles so that you can enjoy higher performance. WARNING Ignoring the WARNING instructions can lead to grave or even fatal injuries for the user, the people nearby or the technicians in charge of its inspection or repairs. Hydrogen gas produced by the battery may explode if exposed to open flame or sparks. Keep flames and sparks away from the battery. CAUTION This symbol identifies instructions or procedures which, if not strictly observed, may damage or destroy your vehicle. NOTE This symbol indicates points of particular interest for higher efficiency and a more convenient operation of the vehicle. Inadequate driving may lead to environmental problems and conflict with other people. Riding your vehicle responsibly will ensure that you don't have to face these problems and conflicts. WILD HP -69- TABLE OF CONTENTS Front and rear brakes.......................................85 Fuel................................................................85 Cooling system...................................................87 Chain....................................................................87 Throttle grip........................................................................87 Lights...........................................................................87 Tyres.................................................................87 - Use of the QUAD.............................................................89 Engine start.....................................................................89 Gear box..........................................................................90 Starting the vehicle...........................................................91 Stopping the engine..........................................................91 Engine running-in..............................................................92 Parking in inclined surfaces.............................................92 - Driving the QUAD. Practical recommendations...............................93 Become familiar with your QUAD......................................93 Drive with care and common sense.................................93 How to turn with your QUAD............................................94 Uphill climbing..................................................................95 Going down slopes...........................................................95 Going across slopes...........................................................95 Going across shallow water.................................................96 Riding in rough terrain....................................................96 Sliding.............................................................................96 - Tuning............................................................................................97 Tuning the front suspension...........................................97 Tuning the rear suspension...............................................98 - Presentation........................................................................68 Common advice.......................................................................69 Table of contents.....................................................................70 Specifications.......................................................................72 Safety information.................................................................73 Important information..........................................................75 Identification numbers.............................................75 - Loction of components.........................................................77 - Main parts of Quad............................................................79 Contact Key........................................................79 Start the engine...............................................79 Lights..............................................................79 Warning lights..................................................80 Throttle grip.....................................................80 Clutch lever......................................................80 Front brake lever................................................81 Rear brake pedal..............................................81 Emergency stopping...........................................81 Gear pedal..................................................82 Stárter..........................................................82 Seat...................................................................83 Batery................................................................83 Front guard..........................................................83 Rear guard..........................................................83 Footrest........................................................84 Foot protection.....................................................84 - Checkings to be made before riding the vehicle..............85 WILD HP -70- - Periodic maintenance and adjustment..........................................99 Maintenance chart.........................................................99 Cluth lever adjustment..................................................100 Adjustment of the brake lever and pedal.....................100 Checking the brake fluid level.......................................101 Checking the brake pads at the front and rear..............102 Wheel change..................................................................103 Swing arm axle...............................................................103 Adjustment and lubrication of the chain guide.................103 Checking the cooling liquid level.................................104 Air filter..........................................................................106 Spark plug maintenance................................................108 Inspection and lubrication of the cables...........................110 Replacing the lights.......................................................110 Transmission................................................................112 - Cleaning, lubrication and storage.................................................121 Cleaning........................................................................121 Lubrication........................................................................122 Storage...........................................................................123 - Multifunction..................................................................................118 - Torque Table...........................................................................119 - Bolt and Nut tightening.......................................................120 - Troubleshooting...........................................................................121 - Warranty regulations......................................................................126 WILD HP -71- SPECIFICATIONS ENGINE Cylinder size: Type: Cooling system: Bore x Stroke: Injection system: Ignition: Clutch: Gear box: Transmission: Start: FRAME Frame: Front suspension: Rear suspension: Front brake: Rear brake: Rims: Front tyre: Rear tyre: Kick starter: Engine, disc and chain ring shield: DIMENSIONS Wheelbase: Total width: Void weight: Fuel capacity: 449 c.c. Single cylinder, four stroke with 4 valves cylinder head. Líquid cooled. 95 x 62,6 mm. MAGNETI MARELLI. Integrated on EFI. Hydraulic multidisc in oil bath. 6 gears. Primary with gears, secondary with chain. Electric starting and aditional kickstarter pedal. Multi-tube twin-spar frame, Cr-Mo steel made. Wishbone arms with two ÖHLINS multi-adjustable shock absorbers. Aluminium allow swing arm with no welding. Progressive system with multiadjustment ÖHLINS shock absorber. Two self-ventilated 180mm discs with floating two-piston BREMBO caliper. 220mm self-ventilated disc with floating twin-piston BREMBO caliper. Aluminium. 21 x 7,00 ­ 10". 20 x 11,00 ­ 9". Forged aluminium. Forged aluminium. 1.280 mm. 1.300 mm. 175 Kg. 18 litres. WILD HP -72- SAFETY INFORMATION WARNING Not following these instructions may lead to grave injuries or even death. The QUAD is not a toy: driving it may be dangerous. The QUAD is driven differently form from other vehicles such as cars and motorbikes. Even during routine manoeuvres like turns, driving on hills or over obstacles, collisions or tumbles can be quickly produced, if precautions are not taken. - Do not drive the QUAD before reading the sections: "Safety information", "Use of the QUAD", and "Main parts of the vehicle". Even if you are an experienced QUAD driver, not all makes and models are equal and it is necessary to know the machine in depth before starting on your first outing. - You are not allowed to carry a passenger, and the vehicle is not equipped for that purpose. - Sit correctly with both hands on the handlebars, your feet on the footrests and your back straight up. - Always control your speed according to your skills, the weather conditions and the ground characteristics. Pay attention to changes in the ground surface and control your speed when you are not familiar with them. - Always perform the routine checks described in this manual before using the vehicle, to make sure it is in perfect operating conditions, - Riding a QUAD is not like driving any other vehicle, and you will notice it specially when cornering. Practise on flat ground with free of obstacles and with no other vehicles around first. Read the recommendations in the section "Use of the QUAD" of this manual. - The same applies to steep climbs or descends. Start testing your skills with minimum slopes and raise the difficulty level little by little. Advice on this point is also included in the section mentioned above. - In case you stall the engine, follow the procedure described in the manual. If the engine stalls and the vehicle starts going backwards, follow the special braking procedure described in the manual. Climb off the vehicle to the higher side of the slope. - Remember that your safety comes before the machine's, and it is important to keep this priority in mind. -When going across a slope, move your weight to the higher side, read the manual's advice on that. Avoid very slippery slopes or with loose surface. - Never try to overcome big obstacles, like rocks or trunks. This vehicle has not been designed for that; it could be damaged and/or you might be injured. - Do not try to make the vehicle slide sideways if you don't dominate the technique in depth, because it may be dangerous. Like in the cases described above, do some testing on flat, wide and obstaclefree ground beforehand and follow the advice described in this manual. You must never lose control of the vehicle. - This vehicle has been designed to go through a maximum depth of 35 cm of water. Do not use the vehicle in fast moving water, read the instructions for this type of terrain carefully. Take into account that brake efficiency is diminished when wet. When coming out of the water, brake several times so that they dry more quickly through friction. - Always use the tyre size and type described in this manual. WILD HP -73- WARNING - Always stop the engine before refuelling. - While refuelling, do not smoke, fuel is highly flammable and may explode under certain conditions. Keep the engine off at all times. Make sure the area has good ventilation and free of sparks of flammable sources; this includes lamps. The fuel might catch fire and cause serious burns. Avoid spilling fuel over the engine, exhaust or muffler. - When transporting the quad using a trailer, make sure it is upright ant that the fuel tap is in the OFF position (closed). Fuel leaks might take place in the carburettor or in the fuel tank otherwise. - Fuel is poisonous. In case of accidental ingestion, abundant vapour inhalation or contact with your eyes, go to the doctor at once. If fuel gets in contact with your skin, wash it with water and soap. Should you clothes get wet with fuel, change them. - Always ride your quad in well-ventilated areas. Do not start the engine or keep it running in closed facilities. The exhaust vapours are poisonous and may lead to loss of consciousness or even death in a short time. WILD HP -74- IMPORTANT INFORMATION The vehicle leaves the factory with some unassembled elements, to make transportation easier. The dealer will make sure each element is correctly fitted and you will receive the quad ready to use. This paragraph is purely for your information. You will find enclosed a carburettor-adjustment kit. The adjustments must be performed by an expert and only when it is necessary. The carburettor is already tuned, so changes to its settings are initially not required. A spanner for chain tensioning is also enclosed to adjust the chain tension and centre the swing arm axle. Do not lose it; you will make good use of it. 5 5. Chain and swing arm axle adjustment spanner. IDENTIFICATION NUMBERS 4 1 2 3 4 Write down your vehicle's identification number (serial number), the information in the model label and the key identification number in the gaps, to make paperwork easier should any spares be required or as a reference in case of robbery of the vehicle. Serial numbers It is located at the front (A). It indicates the frame number the vehicle is registered with. 1. Chain guard. 2. Swing arm guard. 3. Footrests. 4. Foot protectors. WILD HP -75- SERIAL NUM. NOTE The vehicle's serial number is used for your machine's identification. HOMOLOGATION B. Key identification number The quad has two pairs of keys. The first and most important (C) is the contact key, and the second (D) is used for the fuel tank and seat locks. The identification number is located right where the two keys are linked, as shown in the picture. This number must be mentioned to order a new set of keys in case you lose them. (B) (A) (C) (D) Homologation badge Your quad has its corresponding homologation badge (B), where its serial number is printed. It is also printed at the front, and it must coincide with the documents. You are recommended to write down the data in the chart below. KEY ID. N. WILD HP -76- LOCATION OF COMPONENTS GAS GAS WILD H.P. 450 11 12 1 23 4 56 7 89 10 13 14 15 1- Clutch lever 2- Light switch 3- Flash beam 4- High beam 5- Emergency stop 6- Contact key 7- Parking brake 8- Starting button and stop engine 9- Front brake lever 10-Throttle grip 11-Front guard 12-Brake pads 13-Fuel tank cap 14-Footrest grids 15-Rear protection WILD HP -77- 15 16 17 23 18 19 20 21 22 24 25 26 15-Headlight fairing 16-Full-throttle body 17-Seat 18-Front shock absorber 19-Engine 20-Gear pedal 21-Swing arm 22-Exhaust pipe 23-Front brake fluid 24-Kick starter pedal 25-Brake pedal 26-Oil tank WILD HP -78- MAIN PARTS OF THE QUAD CONTACT KEY The key (A) is located on the front part of the handlebars. To turn the contact on, turn the key clockwise to the "ON" position. To turn contact off, turn the key anti-clockwise to the "OFF" position. LIGHTS NOTE The headlight and the rear light can only be switched on when the engine is on. Short beam Low beam Whithout lights Switch (A) slides into three positions, we will find it in the "OFF" position. (A) START THE ENGINE This quadricyle has been fitted with an electric starting mechanism and a pedal-operated one. Control (B) is on the right-hand side of the handlebars. Pedal (C) is located on the right-hand side of the quadricycle. You will find it in the rest position. Pull this control until it reaches its work position. (A) (C) (B) (A). Light indicator. (B). High beam. (C). Blow of high beam. (D). Indicators. (E). Horn button. (E) (D) Press the red button (B), located to the right of the switch above, to switch to high beam (Position: ). The high beam can only be turned on when the short beam is on. (B) (C) Slide switch (A) down to the OFF position to turn off the headlight and the rear light. WILD HP -79- Indicators (D) are located in the lower part of the left grip. Sliding the switch to the right turns on the right indicator, and the same action to the left applies to the left indicator. In the same group we will find the horn button (E). EMERGENCY INDICATORS It is a button on the front part of the vehicle (F), before the handlebars. It also works with the contact off. When on, a light inside the button will flash. NOTE Regarding the use of this lights, follow the legal conditions of each country. (G) WARNING If the throttle is not working properly, it may be difficult to accelerate or slow down as you wish. This may cause accidents. Check the correct operation of the throttle before starting the engine. If the throttle does not work smoothly, check for the cause. Solve the problem before using the machine, or go to a specialised workshop. CLUTCH LEVER The clutch lever is located on the left side of the handlebar. Activate it to engage or disengage the clutch (H). To make the clutch work smoothly, the lever must be pulled quickly and released slowly. (F) THROTTLE GRIP Before starting the engine, check that your throttle works smoothly (G). Make sure it slides back to idle when the grip is released. The grip has a spring to return the engine to idle and slow down the vehicle when the hand is taken off the grip. (H) WILD HP -80- FRONT BRAKE LEVER (D) The front brake lever (A) is located on the right side of the handlebars. Activate it to apply the front-wheel brakes. (C) (A) One end (C) is attached to the vehicle and the other end (D) is attached to the rider. The cable is elastic, and the two ends are joined to the rider and the vehicle, with the part joined to the vehicle sensitive to sudden movements and easily released in such cases. When released, it automatically stops the engine. NOTE Make sure you release the parking brake before operating the throttle. You are recommended to attach the cable to a strong point, as it is important that the cable is not accidentally released in any case. (For example, the cable may be attached to your trousers, jacket, to your wrist... but always to a part where it will not come off easily). WARNING EMERGENCY STOP The vehicle features an emergency stop system. This mechanism prevents the vehicle from running on in case the rider should fall. The vehicle must not be used without attaching the emergency stop system. Ignoring this order may cause serious consequences. REAR BRAKE PEDAL The rear brake pedal (B) is located on the right side of the lower chassis. Activate it to apply the brake to the rear wheels. (B) WILD HP -81- CHANGE PEDAL The vehicle features a 6-speed gearbox. The change pedal (E) is located on the left side of the engine and is used in combination with the clutch when changing gears. For use, pull up the choke knob (A), and without turn the twist grip, start the engine. Look the engine that starts with high revolutions. Waiting few seconds, the engine will be a good temperature. For pull down the choke button, only drive the twist grip. (E) NOTE - If the engine is choked, start with the throttle fully open. - You can use the clutch to start the motorbike with a gear in. FUEL TANK CAP To open the fuel tank, turn the key anti-clockwise. STARTER The starter (F) is a mechanism that opens the throttle to a certain degree, without having to move the throttle grip, so as to favour the engine when cold. The engine will reach the optimal operating temperature in a short time and with no need to force it. (F) WILD HP -82- SEAT To remove the saddle, use the same key that was used to open the petrol-tank cap (B). Insert the key into the lock located on the righthand side of the QUAD. Turn the key clockwise, and then insert your hand through the rear, between the saddle and the frame. The saddle will lift easily. NOTE When putting the seat back in the normal position, make sure it holds well back in place. - Charge duration = 6 hours minimum / 24 hours maximum. 3.2. Charge mode with constant power. - Maximum charge power = 0.1 Cn. - Recommended charging time = 5 - 8 hours. - The product of (charging power) x (charging time) has to stay within the range:0,5 - 0,8 Cn. NOTE In case charging modes different than the established ones are used, by no means, may the maximum allowed power or the charging time of 24 hours be surpassed. CAUTION Exceeding charge standards may reduce the life cycle of the battery. Never surpass charge standards. (B) CAUTION Inverting the polarity of the battery terminals may cause battery charge problems and cause damage to it. The red terminal is the positive (+) and the black terminal is the negative (-). BATTERY This battery is maintenance free and checking the fluid level is not required. It is recommended to check the charge of the battery periodically. The operating instructions for the battery are as follows: 1. 2. Check the battery tension while the circuit is open. In case the battery's tension is below 12.60 V, or if the storage period has exceeded 6 months,the battery has to be recharged following the instructions in paragraph. In case the tension is above 12.60 V, the battery can be installed on the vehicle without having to recharge it. 3.1. Charge mode with constant tension. - Constant tension = 14.40 - 14.70V - Initial charging power = 0.1 - 0.5 Cn FRONT GUARD The front guard projects from the quad. In case of a front crash, the protection, attached directly to the frame, will absorb the crash and prevent the steering and the rest of the vehicle from suffering significant damage. WILD HP -83- REAR GUARD Likewise, the rear guard (D) also projects from the vehicle. It will prevent the quad from falling backwards, which might result in serious injuries. (D) (E) NOTE In case of steep climbs, the rear guard will not prevent a backward tumble, so be prudent in climbs and examine the ground carefully. FOOTRESTS WARNING The footrests and protectors are an essential protection system for the quad's safe riding. The quad has very wide wheels and it would easily drag your leg under the wheels, causing serious injuries. The QUAD features two footrests (E), one on each side. Both footrests have a grid. The package will protect our feet and legs in case of losing balance and taking your feet off the rests. Their width allows for great freedom of movement. FOOT PROTECTIONS The foot protections (F) are located between the footrests and the wheels, and they are an additional protection system to the footrests. By filling the gap, we have eliminated the possibility to damage our lower limbs with the wheels. (F) WILD HP -84- CHECKINGS TO BE MADE BEFORE RIDING THE VEHICLE WARNING Always inspect the quad before every use, to make sure it is in safe riding conditions. Always follow the inspection proceedings and programmes described in this manual. Failure to inspect the machine increases the risk of accident or breakdown. FRONT AND REAR BRAKES WARNING Always check the brakes before riding. Do not drive the QUAD if you find a problem in the brakes or if braking capacity may be reduced, because it might lead to an accident. Should you discover any problem that cannot be solved using the proceedings described in this manual, go to a specialised workshop to have the QUAD inspected. Disc wear-out is automatically compensated and does not have any effect on the brake lever or pedal. The only adjustments required are the brake lever free play, the pedal position and its free play. Brake lever and pedal Check the free play in the front brake lever (1). Should it be noticeable, check the state of the brake pads and look in the "Adjustments and Maintenance" section of this manual Make sure the free play of the brake pedal is not excessive (2). 2 1 Check the brake pedal position. If you do not find it correct, have it adjusted at a specialised workshop. Check the operation of the lever and pedal. They must move smoothly and when applying the brakes the sensation must be of firm grip in both of them. Otherwise, have a specialised workshop inspect you vehicle. Brake liquid level Check the brake liquid level. Add liquid if necessary. (See "Maintenance" section of the manual) Recommended liquid D.O.T. 3 o D.O.T. 4 NOTE The vehicle is fitted with D.O.T.4. as standard. Brake liquid leaks Check for brake fluid leaks in the pipe joints or fluid reservoirs. Brake firmly for a minute. In case of a leaking, have a specialised workshop inspect your vehicle. WILD HP -85- (A) Make sure the fuel tank has enough fuel. (B) NOTE You are recommended not to let the fuel level run too low. In case of dirt at the bottom of the fuel tank, it would enter the engine and might damage it. Be careful not to spill fuel, specially on the engine or the exhaust, as it may start a fire with risk of serious burns. Dry the spilt fuel at once with a cloth. Make sure the fuel tank cap is tightly closed. Recomended fuel CAUTION Use only unleaded fuel. The use of leaded fuel would seriously damage the inner parts of the engine. Brake operation (A) and (B). Front and rear brake fluid reservoirs. Test the brakes while riding slowly after starting, to make sure they work to perfection. If the brakes do not work correctly, inspect the brake pad wear-out. FUEL The GAS GAS WILD H.P. 450 c.c. has a 4-stroke engine that requires a 98 gasoline. OCTANE RATING METHOD Antiknock Index (RON + MON) 2 Research Octane No. (RON) MINIUM RATING 90 90 WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Always stop teh engine and do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. WILD HP -86- COOLING SYSTEM Radiator pipe Check that the radiator pipes do not have cuts or are damaged, and that none of the joints have leaks. Radiator Check the radiator fins for obstructions with, for example, insects or mud. Clean them with water at low pressure. CAUTION The use of high pressure water when washing the quad may damage the radiator fins and decrease its efficiency. Do not obstruct or deflect the air intake to the radiator by fitting unauthorised accessories. Interfering with the air intake may overheat and damage the engine. Cooling liquid It absorbs the excess heat from the engine and transfers it to the air through the radiator. If the liquid level falls, the engine overheats and may be seriously damaged. Check the cooling liquid level in its reservoir (A) with the cold engine (the liquid level will vary with engine temperature). The level is correct when between the two marks. If it falls below the lower mark, add anti-freezing liquid. Change the liquid every two years. NOTE The liquid must be right between the two marks, not above the top mark or below the bottom one. CHAIN Check the overall state of the chain and its tension before each outing. Lubricate and adjust the chain if required (See section 12 of Maintenance). THROTTLE GRIP Check the throttle grip for correct operation, It must accelerate smoothly and return to the idle position when released. If required, revise the grip and grease the moving parts so that it works correctly. LIGHTS Check the headlight and the brake lights to make sure they are in perfect conditions. Make any necessary repairs to make them work to perfection if required. TYRES (A) Always use the recommended tyres. WILD HP -87- WARNING The use of inadequate tyres or riding the vehicle with incorrect or unequal tyre pressures may lead to loss of control, with the subsequent risk of accident. Tyre wear-out limit: Observe how the tyre wears out. If the tyre is worn out at the centre, it means that the pressure is too high. If the tyre wears out at the edges, the tyre pressure is too low. The tyre must be worn out equally on its surface. Replace the tyre when the groove depth is below 3mm. Manufacturer Front Rear MAXIS MAXIS Size 21 x 7,00 - 10" 20 x 11,00 - 9" Type RAZR RAZR The tyres must be inflated to the recommended pressures. Measure the tyre pressure with a low pressure gauge. CAUTION Check and adjust the pressures with cold tyres. Pressures must be the same on both sides. 1 Recommended Front Rear 0,400 bar/ 40 Kpa 0,450 - 0,500 bar/ 45 - 50 Kpa Minimum 0,370 bar/ 37 Kpa 0,420 - 0,470 bar/ 42 - 47 Kpa Maximum 0,430 bar/ 43 Kpa 0,480 - 0,530 bar/ 48 - 53 Kpa Minimum stud depth (1): 3 mm. WILD HP -88- USE OF THE QUAD WARNING Read the User's Manual carefully so as to become familiar with all the commands. Loss of control may cause an accident or injuries. ENGINE START CAUTION Before starting the engine for the first time, consult the section "Engine running-in". WARNING In cold weather, make sure that all the cables work smoothly before you go out on your quad. If the cables are frozen or do not operate smoothly you could lose control of your QUAD and have an accident. 1.- To activate the parking brake, pull the brake lever while using the lock lever. WILD HP -89- WARNING - Always use the parking brake before you start the engine. The QUAD might start unexpectedly if the brake is not on. This could lead to a loss of control or to a crash. - Remember to release the parking brake before starting. The brake could overheat if the quad is used without releasing it. It could lose efficiency and cause an accident. It would also wear out prematurely. 1.- Put the gearbox into neutral. 2.- Turn the contact key (A) clockwise (position "ON"). 4.- If the engine is cold, pull the start button (B). (B) 5.- Without turning the throttle, start the engine. NOTE If the engine does not start, turn the key to the "OFF" position and wait some seconds before trying again. You should try to start the engine for few seconds each time, so as to save battery charge. GEARBOX (A) This vehicle features a 6-speed gearbox. It is a return-type change, which means that we must go through second gear to change from first into third, that is, one gear at a time. 3.- Attach the lose end of your emergency stop system to yourself (see recommendations in the section "Main parts of the motorbike/ Emergency stop"). To insert the first gear from neutral, we must first pull the clutch lever, step on the change pedal and slowly release the clutch. (In the next section the process of starting the vehicle is described in more detail). CAUTION When changing gear, push firmly the change lever to ensure positive changes. If the change is not completed, it may cause the transmission to change into another gear and damage the engine. WILD HP -90- CAUTION Do not run with the engine off for a long time, or tow the machine during long routes. Even in the neutral position, the gearbox lubrication is only activated when the engine is on. Inadequate lubrication may lead to breakdown. STARTING THE VEHICLE 1.- Activate the throttle. To slow down To slow down or stop, release the throttle and apply the brakes smoothly and uniformly. As the vehicle slows down, change into a shorter gear. Before changing into a shorter gear, wait for the engine revs to fall to the adequate level. An incorrect use of the brakes or the change may cause the tyres to lose traction, with the subsequent loss of control and risk of accident. WARNING CAUTION Release the throttle to change gear, otherwise the engine and transmission may be damaged. 2.- As we have already explained, the clutch must be activated to insert the first gear from neutral, then the change pedal must be pressed and the clutch must be released slowly as the throttle is gradually increased. 3.- Once the desired speed has been achieved, release the throttle and, at the same time, activate the clutch lever quickly. 4.- Change into second gear (be careful not to insert neutral). 5.- Activate the throttle partially and release the clutch lever gradually. 6.- Follow the same procedure to change into higher gears. Make sure the engine's revs are low enough to change into a lower gear. If the revs are too high when changing into a shorter gear, the wheels might stop turning. This might lead to loss of control, with risk of accident and injuries. It can also damage the engine and transmission. STOPPING THE ENGINE 1.- Change into neutral. 2.- Push the stopping button (A). WARNING Too brisk acceleration or releasing the clutch lever too quickly may result in an accident and may cause the vehicle to slide and tumble. The throttle must be gradually turned and the clutch must be smoothly released. (A) WILD HP -91- ENGINE RUNNING-IN The running-in process is a very important part in the life of your quad, and we recommend you to follow the instructions below carefully. NOTE The running-in period is a time (usually the first 20 hours of use) in which we must take into account several points for the engine tuning. During the first 10 hours you are recommended not to use more than halfthrottle for long periods or in any situation that may cause engine overheating. On the other hand, short accelerations - for 3-4 seconds - are beneficial for the engine and will not be a problem for it. Each acceleration sequence must be followed by a resting period, so that the engine can release all the heat it has generated. During this 10-hour period, try not to run at constant speed, vary your speed now and then. Durante las siguientes 10 horas (10-20), se recomienda no rodar a más de ¾ de gas durante un largo período. Over the next 10 hours (from 10 to 20) try not to use more than ¾ throttle for long periods of time. (A) (B) 3.- Turn the contact key (A) anti-clockwise (position "OFF"). PARKING IN INCLINED SURFACES WARNING Avoid parking on inclined ground, as the quad may start moving without control, with risk of accident. If it is necessary, insert the first gear, apply the parking brake and block the front and rear wheels with rocks or other objects. 1. Use the brakes to stop the vehicle; once it has stopped, insert the first gear. 2. Without releasing the clutch lever, stop the engine. Now you can release the clutch lever. 3. With both the front and rear brakes pressed, activate the parking brake and take your foot slowly off the brake pedal. WILD HP -92- 4.- Use the parking brake (B) to park inn the vehicle. 5.- You can take the key off the lock now. DRIVING THE QUAD. Practical recommendations. BECOME FAMILIAR WITH YOUR QUAD This quad is destined to expert riders, to be used in recreational activities. Even if you are an expert with other types of off-road vehicles and motorbikes, riding the quad requires special skills which can only be achieved through practice. We recommend you to start becoming familiar with your vehicle on flat land with no obstacles, and without the presence of other drivers. Do not try difficult manoeuvres until you are totally familiarised with you QUAD. A QUAD is not designed to jump over obstacles, refrain from doing it as the vehicle could be seriously damaged. WARNING Never carry a passenger. Carrying a passenger may result in an accident and the subsequent risk of bodily harm to the rider and/or the passenger. The quadricycle features an emergency-stop system in case of rider fall, but it has not been designed to cope with passenger falls. THE QUAD WILD IS NOT APPROVED FOR CARRYING PASSENGERS. ONLY THE RIDER MAY USE IT. Equipment - You must wear an approved helmet of your size at all times. - You must also wear: eye protection, gloves, boots, long-sleeve shirt or jacket and long trousers. WARNING WARNING Do not drive the quad without reading this manual before. Make sure you understand how to use the commands and pay special attention to the section "Information on your safety" It is essential to wear the full equipment mentioned above, otherwise the risk of serious injuries or even death is increased. Checkings before riding For the correct safety and care of the quad, always do the checkings before riding. They are explained in detail in the section "Checkings to be made before starting the vehicle." While riding Always ride with the footrests and protections fitted, they will protect you from serious injuries in the legs and feet. Keep your feet on the footrests at all times while moving and keep the two hands on the handlebars. DRIVE WITH CARE AND COMMON SENSE As we have already commented, driving your quad requires special skills which can only be achieved through continuous practice over a certain period of time. Take your time to learn the basic techniques before attempting more difficult challenges. WILD HP -93- WARNING As we have explained in this manual, the use of the footrests and the protections is essential for your physical integrity. Modifications Do not modify this QUAD by fitting or using inadequate accessories. The parts and accessories added to this vehicle must be original GAS GAS parts or equivalent parts designed for their use in this quad, and must be fitted and used according to the instructions. Fitting inadequate accessories or modifying the vehicle may provoke changes in the machine's handling, which, in certain conditions, might lead to an accident. In case of doubt, consult an authorised dealer. Exhaust system The QUAD's exhaust system's temperature rises with the use. To prevent burns, do not touch it. Park the quad in an adequate place or somewhere far from the reach of pedestrians or children. When approaching the corner, slow down and start to turn the handlebars towards the desired direction. Lean your body to the inside of the corner to compensate the inertia produced by speed. Use the throttle to keep a uniform speed all through the corner. This will allow you to take the corner correctly. This picture shows you how to do it. 1 1.- Turn right. 2.- Turn left. 2 HOW TO TURN WITH YOUR QUAD At low speeds you will have no problem to turn the handlebars. On the other hand, if speed increases the difficulty to turn will increase. The back wheels are rigidly mounted on the same axle and turn at the same speed, so the quad will resist turning into corners unless the inside wheel loses some traction. A special skill is required to turn, and it is important to learn the skill on flat land, with no obstacles and at moderate speed. If the technique used is not correct, the quad will probably continue straight. If it does not turn, stop and practise the proceeding again. If the vehicle starts to incline to the outside of the corner, reduce your speed, turn the handlebars or lean even more to the inside. It may also be necessary to reduce your speed gradually and to turn the steering to the outside of the corner to avoid tumbling over. WILD HP -94- UPHILL CLIMBING You are recommended to start gradually in slopes with little inclination and increase the inclination as your practice improves. Avoid loose or slippery surfaces or obstacles at any time. As we have already commented, the quad has not been designed to jump over obstacles, so please refrain from doing that. If you are climbing a slope and you discover that you have not guessed correctly your ability to reach the top, turn the quad round while you still have some traction and if there is enough room for the turn and go down. If the vehicle starts going backwards, do not use the rear brake or try to insert a gear, the quad might easily tumble backwards. Get off the vehicle immediately over the high side of the climb. Always keep your safety in mind as a priority. GOING DOWN SLOPES 4.- When descending a slope with the QUAD, transfer your weight to the back, to the high side of the climb. Move back in the seat and sit there with your arms well extended. 3 4 3.- It is important to transfer your weight to the front part of the quad in climbs. You can do that by leaning forward and, if the slope is very steep, standing on the footrests and leaning over the handlebars. The picture shows you how to do it. WARNING Do not accelerate or change gear briskly. The QUAD might lose balance and tumble backwards. In this case the rear protection would not help you, as your inertia speed would be considerable. Never go over the top of a climb at full speed. There might be an obstacle, a steep descent, another vehicle or a person after it. Select a short gear that allows the engine compression to act as the main brake. Braking incorrectly may lead to losing traction. The picture shows you the correct position. GOING ACROSS SLOPES To cross a slope with your quad you must place your weight to help you keep the balance. Before attempting to go across the slope, make sure you have learnt the basic skills on flat ground. Avoid WILD HP -95- slippery sections and rough terrain that may cause you to lose balance. While you are crossing the slope, keep your body inclined towards the top of the climb. It might be necessary to correct direction by turning the steering slightly uphill. When crossing slopes, do not perform tight turns up or downhill. If the quad starts to lose balance, turn gradually downhill if there is not an obstacle in your way. When you have regained balance, turn the steering back to the correct direction you are heading for. GOING ACROSS SHALLOW WATER With the QUAD you can, at slow speed, cross shallow water with a maximum depth of 35 cm. Before entering the water, choose carefully where you are going to cross. Choose a place with no steep descends and avoid rocks and other obstacles that may make you slip or lose stability with the QUAD. Drive carefully and slowly. WARNING Do not cross fast waters or waters deeper than specified in this manual. Remember that the brakes will get wet and lose efficiency to stop the machine. Check the brakes after leaving the water. Use them several times to make them dry if necessary. NOTE After crossing water with the quad, eliminate the water that might have entered the system by unplugging the retention tube at the bottom of the filter box. Wash it in fresh water if you have driven across salt water or mud. RIDING IN ROUGH TERRAIN Riding in rough terrain must be performed very carefully. Be always alert to any obstacle that may damage the QUAD, make you lose balance or cause an accident. Keep your feet firmly placed on the footrests at all times. Avoid jumping over obstacles with the vehicle. It might cause you to lose control and damage the machine. SLIDING When riding over slippery or loose surface, do it carefully as the QUAD could slide. An unexpected slide not corrected in time could result in a serious accident. To reduce the tendency of the front wheels to slide on slippery surfaces, sometimes it is useful to put your weight on them. If the rear wheels start to slide sideways, you can usually regain control by turning the handlebars towards the slide, if there is enough room to do that. You are not recommended to accelerate or brake until you have corrected the slide. With practice, after some time you can dominate the controlledsliding technique. Before attempting to do so you must choose the adequate ground carefully, as both stability and control are reduced when doing them. Take into account that you must avoid sliding in extremely slippery surfaces, like for example ice, as you could lose control completely. NOTE Learn to control your slides safely by practising at slow speed on flat ground with no inclination. WILD HP -96- TUNING (A) TUNING THE FRONT SUSPENSION The front suspension is formed by two wishbone arms with 2 multipleadjustment ÖHLINS shock absorbers. To adapt to the different types of riding conditions, the shock absorber springs can be adjusted or replaced by another optional unit. The tension can be easily adjusted, so it is not necessary to change the oil density. To adjust the rebound, turn the knob (B) in the lower part of the shock absorber with your hand. There are 22 available positions, each one of them reached by turning the knob until you feel a "click". The shock absorber comes regulated to 7 clicks as standard. Turn the knob clockwise until the end, now it is totally closed. Turn the knob anti-clockwise 7 clicks, and it is in the standard setting. Leaving it in the 0-click position makes it very hard, while position 22 makes it very soft. WARNING (B) Always adjust the right and left absorbers with the same measure. Unequal adjustments will cause handling problems and loss of stability, with the subsequent risk of accident. Compression adjustment Rebound adjustment WARNING Suspension parts will be hot during operation. Never touch the compression shock absorber, the rebound adjustment or the oil reservoir with naked hands or unprotected skin until they have cooled down. The total number of available positions is 38 clicks. The standard setting comes with 20 clicks. Hard compression setting is 0 clicks. Totally soft compression is 38 clicks. For the compression adjustment, turn the knob (A) at the top of the shock absorber with your hand (in 2002 models a flat tip screwdriver is required for this operation). Turn the knob clockwise to the end and you will close it totally. WILD HP -97- TUNING REAR SUSPENSION It is an unwelded aluminium alloy swing arm. The progressive strut system features an ÖHLINS multi-adjustment shock absorber. Like the front suspension, it can be adapted to different riding styles. Adjusting rebound To adjust the rebound, turn the knob located in the lower part of the shock absorber (C) manually. There are a total of 28 possible adjustments. The standard setting is 13 "clicks". Turn the knob clockwise to its end, now it is totally closed. Turn 13 "clicks" anti-clockwise and now the setting is the standard one. With 0 clicks, the rebound would be very hard, and with 28 clicks would be very soft. There are 56 positions available in total. The standard setting is 28 "clicks". Totally hard compression is 0 "clicks". Totally soft compression is 38 "clicks". (A) Adjusting compression To adjust the compression settings, turn the knob on the top end of the shock absorber with a flat tip screwdriver. Turn it anti-clockwise to the end, which will totally close it. WILD HP -98- PERIODIC MAINTENANCE AND ADJUSTMENT necessary MAINTENANCE CHART Lubricate Change Adjust Prove Clean If it is The first revision must be performed by a specialised workshop at 500 km or after two fuel tanks. The following revisions must be passed every 2,000 km or three months. BEFORE EVERY OUTING WITH THE QUAD Fuel tank level Brake fluid level (front and rear) Brake lever and pedal Free play Brake pads Cooling liquid level Tyre wear-out State of the chain Throttle grip Clutch lever freeplay Lights Switches Quad Change pedal Brake lever and pedal Clutch lever Air filter Air box Chain guide Cables Radiator pipes and connections Exhaust Wheel bearings (10 outings) Check all screws Tightening force chart (check chart) Brake piston and cover dust guard (2 years) Brake pump piston and cover dust guard (2 years) Brake pipe (2 years) WILD HP -99- AFTER EVERY OUTING EACH... Tighten Fill Regular inspections, adjustments and regular lubrication keep the machine in the best possible safety and efficiency conditions. Safety is an obligation for the machine's owner. The most important points related to inspections, adjustments and lubrication are described in the pages below. WARNING Do not perform any maintenance operation with the engine on. The moving elements might catch in your clothes or in a part of your body and cause injuries. The electric parts might release sparks, provoke electric shocks or fire. Before performing any maintenance operation, stop the engine, unless we indicate otherwise. If you are not familiar with the maintenance of the vehicle it is better to go to a specialised workshop. Tighten the adjustment screw to obtain the optimal free play. If the clutch lever adjustment is at its limit, it must be adjusted by using the clutch pump piston push rod. ADJUSTMENT OF THE BRAKE LEVER AND PEDAL The disc wear out is automatically compensated and has not effects on the brake lever or pedal. The only adjustment required is therefore the free play of the front brake lever and the position and free play of the rear brake pedal. Front brake lever The lever free play will initially be directly related to the brake pad wear-out, that is, if you notice that the lever has some free play it would be a good idea to check the brake pads to see if the pads need replacing before proceeding to readjust the lever. CLUTH LEVER ADJUSTMENT The clutch lever free play must be 2-3mm. The free play will increase as the clutch plate wears out, and will require further adjustment. When the free play is excessive, try to adjust the level of the clutch lever first. (C). Front brake lever. (D). Tighten screw. (C) (A). Adjustment screw. (B). Clutch lever. (D) (A) (B) Once this observation has been performed you may adjust the lever until you feel it falls naturally to your hand. Tighten the screw (D) depicted in the picture; it is covered by a silicone tube, you must remove it to show the slot where you must insert the screwdriver for adjustment. If you tighten the screw the free play will be smaller and if you unscrew it the lever will have more free play. WILD HP -100- Air might also have entered the brake system. The process to bleed the system is as follows: - Remove the brake fluid reservoir lid (E) to control the level. 10 mm (E) When the brake pedal is in resting position it must have 10-mm free play. Otherwise it will be necessary to adjust it. WARNING If the brake pedal has a spongy feeling when activated, it may be due to air in the pump or to a defect. Both conditions are dangerous for riding, check the brakes immediately. - Remove the brake pad cap (F) (in the inside of the wheels) and attach a transparent tube to its end. CHECKING THE BRAKE FLUID LEVEL (F) NOTE Inspect the brake fluid and change it regularly. You may also change it if it appears to be contaminated with water or dirt. Inspection of the brake fluid Front: The small brake fluid reservoir is located to the left of the throttle grip. If we look at the reservoir carefully we will see one of the sides with a small bubble which will allow us to control what happens inside the reservoir. If you have just purchased your quad, you will see nothing through the bubble because the reservoir is full. You will when the fluid level descends, then you will be able to control the level decrease. - Activate the brake several times. You will see that fluid starts exiting the system through the tube. The transparent tube will help us see if there is air, i.e. bubbles, in the system. - Once the system has been bled, refill the reservoir to the top. Rear brake pedal Check the brake operation and make sure it does not rub against any other part of the QUAD. To adjust the pedal free play, unscrew the locking nut, turn the screw, place the lever in the desired position and re-tighten the locking nut. WILD HP -101- When the fluid level is too low, add more: - With a cross-tip screwdriver, unscrew the two screws on the reservoir. - Next, add the necessary fluid. - Put the screws back in place and make sure the reservoir is tightly held in place. Rear: Below the seat of the vehicle we will find the rear brake fluid reservoir. - Insert the fuel tank key into the lock on the right side of the QUAD right below the seat. - Turn the key. - Put your hand between the seat and the plastic behind the seat and remove the seat. - Make sure that the fluid container is well closed, put the seat back in place and turn the key back to remove it. Ensure also that the seat holds well in place. Recommended fluid Use D.O.T.3 o D.O.T.4 CHECKING THE BRAKE PADS AT THE FRONT AND REAR There are 3 brake calipers: 2 in the front wheels, with one for each wheel; and 1 in the drive chain which brakes the rear wheels at the same time. All of them have the same operating system and we must revise and control them in the same way. As we can see in the picture, the brake caliper is formed by different parts, but we are only interested in the pad here. The pad is the part that rubs on the disc and, as a consequence, is the part that suffers more wear-out and requires more control of its thickness. (D) (C) (A) (B) (C) - You will find a small easy-access reservoir (A). It has two marks, "MIN" and "MAX". The fluid level should preferably be closer to the "MAX" mark. If it is much below it, add fluid. (B). Pad. (C). Brake caliper. (D). Brake disk. WILD HP -102- NOTE Do not wait until the pads are too worn out. If they are not controlled they may seriously damage the brake caliper. When the pad thickness has decreased considerably, go to a specialised parts shop and proceed to replacing it. WHEEL CHANGE We must change the wheels when they are worn out or after a puncture. The process is as follows: (F) (E) - Each wheel has four nuts (E) which we will remove with a no.15 wrench. - Unscrew the nuts and remove the wheel from the axle. - To put them back in place, follow the same procedure in inverse order. ADJUSTMENT AND LUBRICATION OF THE CHAIN GUIDE It must be checked, adjusted and lubricated according to the regular maintenance to prevent excessive wear out. If the chain is too worn out or badly adjusted (too tight or with too much slack) it might go free or even break. WARNING A freed or broken chain might catch in the engine or the rear wheel and damage the QUAD, causing a loss of control. Tension inspection The gap between the chain and the swing arm at the chain guide must be around a finger width, if it were more or less, adjust to the correct measure. Follow the proceedings explained below: SWING ARM AXLE It is very important to have the rear wheel axle well centred, otherwise, if it had some free play, the bearing could be damaged. - To adjust the axle nut, we will go to the rear end of the quad. - The nut is located at the right of the swing arm. - Use the (F) spanner, which comes with your GAS GAS Quad, to tighten the axle. WILD HP -103- - Go behind the quad. You will see four screws on the swing arm (A). - Unscrew the 4 screws of the vehicle. Chain lubrication is one of the actions that you will perform very often. ¿When must you lubricate the chain? - After riding on damp ground. - When it has a dry appearance. - After washing the quad. - If the QUAD has not been used for a long time. (A) The lubrication oil will preferably be dense, as it will stay on the chain longer and lubricate it better. Lubricate on the pin side of the chain so that it filters into them; dry out the oil excess. - With the spanner (B), which comes with your QUAD, adjust the chain correctly. Screw the 4 bolts back in place. CHECKING THE COOLING LIQUID LEVEL The cooling liquid absorbs the engine's excess heat and transfers it to the air through the radiator. If the liquid level decreases, the engine overheats and may be severely damaged. Check the liquid level everyday before riding the QUAD. NOTE The level should not go down in normal conditions. If you must add liquid very often, revise the circuit for leaks and take the quad to a specialised workshop. WARNING To prevent burns, do not remove the radiator cap or try to change the liquid with a hot engine. Wait for it to cool down. (B) NOTE Make sure that the bolts are tightened and that the chain tension is correct. Inspection of the chain state Inspect the chain for damaged links, lost pins, unequal sprocket teeth or damaged teeth. If the drive chain is damaged, go to a specialised workshop and have it replaced. Chain lubrication Good chain maintenance is essential to ensure the correct operation WILD HP -104- Information on anti-freezing liquid To protect the aluminium parts of the cooling system (engine and radiator) from oxidisation and corrosion, use chemical inhibitors in the essence of the cooling liquid. Without an anti-corrosion liquid, in time, the radiator would oxidise. This would block the cooling ducts inside it. CAUTION The use of inadequate liquids may damage the engine and the cooling system. Use cooling liquid with specific anti-corrosion agents for aluminium engines and radiators according to the manufacturer's instructions. WARNING Chemicals are toxic for the human body. Follow the manufacturer's instructions. Distilled water must be used with the anti-corrosion and anti-freezing liquid in the cooling system. If ambient temperature goes down to freezing point, protect the system with anti-freezing liquid. Use a permanent-type anti-freezing liquid (distilled water and anticorrosion glycol ethylene for aluminium engines and radiators) in the cooling system. For the cooling liquid mixture under extreme weather conditions, choose a proportion for low temperature. Cooling liquid level In case of losing much liquid we must check the level in two containers. They are located together on the left side of the quad. (D) (C) Normally, if the level in the reservoir (C) is below the mark we must also check the radiator (D). WARNING Always perform these operations only with a cold engine, the liquids may be hot, and exit the system under pressure, causing serious burns. - Remove the radiator cap and fill it to the top. - Remove the reservoir cap and fill it until the level is between the two marks. - Start the engine and leave it at idle for 15-20 seconds. - Stop the engine and check the levels in the two containers, it will probably have descended because the engine has run out of liquid. - Refill the containers if necessary. WILD HP -105- Coolant Change The coolant should be changed periodically to ensure long engine life. - Wait for the engine to cool completely. - Situate the QUAD so that it is perpendicular to the ground. - Remove the radiator cap. - Place a container under the coolant drain plug, and drain the coolant from the radiator and engine by removing the drain plug at the of the water pump cover. Immediately wipe or wash off any coolant that spills on the frame, engine, or wheels. with a new one, if it damaged. Drain plug tightening torque (look maintenance table) Water pump cover plug: 9 Nm. - Fill the radiator up to the bottom of the radiator filler neck with coolant, and install the radiator cap. - Check the cooling system for leaks. - Start the engine, warm up the engine throughly, then stop the engine. - Check the coolant level after the engine cools down. Add coolant up to the bottom of the radiator filler neck. AIR FILTER CAUTION The air filter must ALWAYS be cleaned after an outing. It would otherwise let dirt into the engine and damage it seriously. (A) (B) (A). Water pump cover. (B). Coolant drain plug. WARNING Coolant on tires will make them slippery and can cause an accident and injury. - Visually inspect the old coolant. If whitixh cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, fluxh the cooling system. - Check the cooling system for damage, loose joints, or leaks. - Install the water pump cover drain plug and cylinder drain plug with the specified torques shown in the table. Always replace the gasket WARNING An obstructed air filter will allow dirt to enter the carburettor and leaves the throttle open. This may cause an accident. A blocked air filter restricts the airflow into the engine, increases the fuel consumption and reduces the engine power, causing spark plug failures. NOTE There is a check hose on the lower part of the air filter box. If dust or water have reached this hose, empty it and clean the air filter element and the air filter box. WILD HP -106- NOTE Do not twist the element when you dry it. (C) 4.- Remove the filter cage. (D) (C). Checking hose. (D). Air filter box. Cleaning process WARNING Clean the filter in a well ventilated area and make sure there are no sparks or naked flames near the working area (that includes a lamp). Do not use petrol to clean the filter, as it might cause an explosion. 5.- Put the filter in a container with some de-greasing liquid. The liquid will clean the filter without damaging it. 1.- Remove the seat and you will see a blue foam right in the centre. 6.- Remove the filter from the bath and let it to dry for some minutes. (E) 2.- Hold the foam and you will see a screw (E) that can be turned with your fingers. 3.- Remove the screw and filter. Remove the filter package from the air filter box. - Inspect the filter for damage, such as scratches, hardened parts, contracted parts... In case of damage, replace it or you will allow dirt to enter the throttle valve. WILD HP -107- NOTE The element must be damp but not dripping. - When the element does not drip anymore we must put it in a lubricant and greasing bath. We can also wet the filter completely and not dip it in a liquid bath, the effect will be the same. Apply special air filter oil to the element foam. If you have no air filter oil, use engine oil. - Also clean the filter cage and the filter box with a damp cloth. - Make sure all the corners are clean before putting all the parts back in place. - Grease all the connections, screws and inlets to the air filter. - Place the filter cage back in position and cover the filter lip with a thick layer of grease to ensure the correct sealing of the system and prevent dirt from entering the carburettor. - Re-install the air filter in the quad and make sure it is correctly fitted. CAUTION Never allow the engine to run without the filter element installed. If you did, non-filtered air would enter the engine and it may result in breakdowns or premature wear-out. On the other hand, using the quad without the filter element may block the carburettor jets and decrease the engine performance and probably cause engine overheating. SPARK PLUG MAINTENANCE The spark plug is an important part of the engine and it is easy to inspect. The state of the plug may indicate the state of the engine. Standard plug: NGK CR8 E o DENSO U24ESR-N 0.7-0.8 mm. The plug must be regularly revised to check the gap and the ceramic insulation. The spark plug should be taken out periodically to check its gap and ceramic insulator. If the plug is oily or has carbon build up on it, clean it (preferably with a (sandblaster) and then clean off any abrasive particles. The plug may also be cleaned using a high flashpoint solvent and a wire brush or other suitable tool. Measure the gap with a wire-type thickness gauge, and adjust the gap, if incorrect, by bending the outer electrode. If the spark plug electrodes are corroded or damaged, or if insulator is cracked, replace the plug. NOTE Inspect every 30 hours. Replace every 60 hours. To find out whether the right temperature plug is being used, pull it out and examine the ceramic insulator around the center electrode. If the ceramic is light brown, the spark plug is correctly matched to engine temperature. If the ceramic is burned whit, the plug should be replaced with the next colder plug. If the ceramic is black, the plug should be replaced with the next hotter plug. NOTE If the engine output decreases, replace the spark plug to regain performance. WILD HP -108- NGK CR7E CR8E CR9E DENSO U22ESR-N U24ESR-N U27ESR-N COMMENTS If the standard plug looks wet or has a dark color, replace. Standar If the standard plug looks glassy or has a white color, replace the plug. WARNING When the injection pump pipes are removed, gasoline may be spilled and cause a fire. Stop the engine before removing the tank. Keep flames and sparks away from the gas cap. Do not smoke. 3. Remove the tank rubber. 4. Unscrew screw of fuel tank. 5. Extract the fuel tank. 6. Extract the protector cap. Spark Plug maintenance CAUTION Incorrect installation of the plug or an incorrect heat range choice may cause extensive engine damage, and such damage would not be covered by the warranty. Use always manufacturer-recommended spark plugs. Consult your dealer or a qualified mechanic in order to know which is the best plug for your motorcycle. Extract the spark plug To remove the spark plug, follow the following steps: 1. Remove the seat.. 2. Disconnect the pump cables (caution: the tubes contain gasoline). 7. Extract de plug and remove the carbon deposits from the spark plug with a small tip or a metallic brush. Readjust the gap in the plug between 0.7 and 0.8 mm (0.028 - 0.031 in.). Before removing the carbon deposits, check its color; this color tells us whether the standard plug is the best for our use. WILD HP -109- NOTE for the correct use of the plug, it is protected by a cap. Keep the cap clean and dry. INSPECTION AND LUBRICATION OF THE CABLES WARNING Inspect the cables periodically and replace them if damaged. When the outside hose is damaged, corrosion may enter the cable. The cables may also be worn out or damaged. The control operation could be restricted, which may result in accidents and injuries. (A). 4 Allen screws. (A) Lubricate the inside of the cable hoses and the cable ends. If the cables do not slide smoothly, have a specialised workshop replace them. Recommended lubricant: Engine oil NOTE Do not touch the shining surface (B) with your fingers, not even with a cloth, as it will easily be scratched. If any dust has settled on it, we recommend you to clean it with a duster. REPLACING THE LIGHTS Front headlight 1.- Remove the headlight fairing, removing the 4 Allen screws. WARNING The bulb is hot when lit and immediately after turning off the lights. Wait for it to cool down before removing it. You could get burnt, or something could catch fire if the hot bulb touched it. (B) (C) 2.- Next, disconnect the speedometer. (C) WILD HP -110- 3.- Unscrew the 3 screws that hold the light from below. Rear lights WARNING The bulb is hot when lit or immediately after turning it off. Wait for it to cool down before touching or removing it. You may get burnt, or fire may catch if the hot bulb touched something. - With a cross-tip screwdriver unscrew the two screws (G) and remove the lens. (E) (D) (D). Cover. (E). Bulb. 4.- Unplug the bulb cable and remove the cover over the rear part of the light. (G) 5.- A piece of wire spring holds the bulb in place (E). (F) (E) (F). Wire spring holds. 6.- After freeing the bulb (E) from the wire part we can remove it from the rear. 7.- Replace the bulb by a new one. To put it in place we will follow the inverse process. - To remove the bulb, press it against the spring, turn it ¼ anticlockwise and replace it with a new one. - Put the lens back in place. NOTE Make sure the lens is well tightened. WILD HP -111- Indicators - With a cross-tip screwdriver remove the screws, located at the rear, and remove the small lens. - To remove the bulb, press it against the spring (A), turn it ¼ anticlockwise and replace it with a new one. 20W-50 15W-40 10W-40 10W-30 15W-50 10W-50 ENGINE OIL (A) ºC TEMP. ºF -22 -4 -14 32 50 68 86 -30 -20 -10 0 10 20 30 - Put the lens back in place and make sure it holds well in place. TRANSMISSION For the transmission and clutch to function properly, maintain the oil level at the proper level. Change the oil periodically. Oil at an insufficient level deteriorates and contaminates rapidly. This accelerates wear and promotes premature failures. Oil level The use of premium-grade four-stroke engine oil will prolong the service life of your motorcycle. Use API-classified SF or SG grade oil. The recomended viscosity is SAE 10W-50, if a SAE 10W-50 oil is not posible, use one of the last table. Checking the oil level and replacing periodicity are two important things for the engine. Begining you have to replace 5 hours ago of the start and then every 60 hours. The oil is pumped from its reservoir into the engine when the engine is running. The level of the oil in the reservoir rises when the motorcycle is not used. The engine-oil reservoir is located at the front end of the chassis. Make sure that the quadricycle is on flat ground. To check the oil level, follow these instructions : Checking the oil level Check both reservoir sight glasses. When in the rest position, the oil should only reach halfway up the lower sight glass. (A). Upper sight glass (B). Lower sight glass (A) (B) WILD HP -112- 1. Run the engine with the motorcycle in neutral gear for 3 minutesRun the engine with the motorcycle in neutral gear for 3 minutes. NOTE When starting the engine, closely follow care and warnings from the "start the engine" section. 2. Wipe both sight glasses clean. 3. Gradually increase the power to 2000 rpm and keep it there. 4. Check to see that the oil covers the whole of the lower sight glass, but does not reach the upper sight glass. If it does, allow the engine to cool down, then drain the reservoir until the optimum level is reached. Cange of oil and filter. The oil should be changed when the engine is hot, since this helps the oil to go out through the drain located in the lowest part of the engine. Follow these steps to change the oil. WARNING The engine oil and the outpour tube can be very hot and cause burns. Wait until the oil and the outpour tube are a little colder, by touching the oil drain with your hand. WARNING Using new or used oil may be hazardous. Permanent contact of oil with the skin has caused skin cancer in many lab animals. Avoid contact of motor oil with the skin as much as possible, to avoid possible skin irritation. - Keep new or used oil away from the reach of childrren - Clean jersey cuffs and pants - Wash yourself with soap if oil has been in contact with your skin. ATTENTION The engine-oil level must remain between the lower and the upper sight glasses. Otherwise, the engine might be damaged. Visually check the oil level while keeping the vehicle fully upright and always before using the quad. NOTE Motor oil expands and descends when it is hot. Check and adjust the level when the motor oil is not hot. To change the oil and the oil filter, follow these instructions: (C) 2. Remove the connection screw (C). WILD HP -113- CAUTION Replace the copper gasket every oil changed. (D) 4. Turn and remove the filter (D) and replace it by another new one. (E) (F) 5. Before replacing the oil filter, make sure that the spring (E) and the o-ring (F) are in the correct position. WARNING Using a filter with an incorrect design may cause engine malfunction. Use the oil filter with the genuine GAS GAS design or equivalent for your motorcycle. WARNING A mistake in the placement of the new element may cause engine malfunction. The motor oil will not flow if the new element is placed incorrectly. . Use a funnel to drain the contents of the oil reservoir. NOTE Recycle and dispose of used motor oil in an appropriate container. (D) NOTE Put a new «o-ring» at the same time the filter is replaced. 9. Replace the filter cover and put the screws that secure the cover, but without tightening them too hard. 3. Remove the three screws next to the filter cover (C). WILD HP -114- 10. Replace the drain caps and screw them back on. Pour new oil through the dipstick hole. Approximately 1800 ml, or else the required amount. WARNING The engine can be damaged if the oil is not used properly or the specifications recommended by GAS GAS MOTOS are not followed. Use the type of oil in the section of «recommended gasoline and oil specifications». 11. Start the engine and let it idle for five minutes. Check that oil is not leaking anywhere. 12. Check that the oil level is correct. CLEANING, LUBRICATION AND STORAGE CLEANING Frequently cleaning your vehicle will not serve only to improve its aspect, but also to improve its overall performance and to make the life of most of its parts longer. Before washing the quad some precautions need to be taken to prevent water from entering some parts: Silencer. Clutch and brake levers, hand grips, engine stop button. - Cover with a plastic bag secured with rubber bands. - Cover with a plastic bag. - Close up the opening with tape or stuff in rags. - Avoid spraying water with any great force near the following places. Air cleaner intake. Spark plug cap and all filler opening cover. - If the outside of the engine has too much grease on it, apply a degreaser with a brush. Do not apply this product to the chain, sprockets or wheel axles. - Eliminate all dirt and the degreaser by washing them off with a garden hose. Reduce the water pressure to the minimum required for this job. CAUTION Excessive water pressure may make it infiltrate in the wheel bearings, brakes, transmission bushings and electric components, with the subsequent damage. WILD HP -115-